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Intermediate dairy mixture and a method of manufacture thereofRelated Patent Categories: Food Or Edible Material: Processes, Compositions, And Products, Products Per Se, Or Processes Of Preparing Or Treating Compositions Involving Chemical Reaction By Addition, Combining Diverse Food Material, Or Permanent Additive, Basic Ingredient Lacteal Derived Other Than Butter Substitute In Emulsion Form, Cheese Or Cheese Type ProductIntermediate dairy mixture and a method of manufacture thereof description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20070202235, Intermediate dairy mixture and a method of manufacture thereof. Brief Patent Description - Full Patent Description - Patent Application Claims
FIELD OF THE INVENTION [0001] The present invention relates to processes for producing dairy mixtures, and in particular, processes for producing an intermediate dairy mixture that is a friable, non-dusting solid cheese base and that is microbiologically stable without refrigeration for extended periods. The present invention also relates to the friable, non-dusting solid cheese bases produced by such processes. The intermediate dairy mixtures of this invention are especially suitable for use in preparing processed cheeses and other cheese products. BACKGROUND OF THE INVENTION [0002] Process cheese is a dairy food product having a smooth, creamy texture and a slight firmness that is desirable to cheese consumers. It is conventionally prepared by grinding and heating one or more varieties of natural cheeses to form a process cheese base. The resultant cheese base is then blended with other dairy products to produce a homogeneous, pumpable fluid cheese material that may be formed into blocks, sheets, slices, or other desired forms. Depending on the particular cheese to be produced, the cheese base may be blended with various amounts of non-fat dairy milk, whey solids, emulsifying agents, or other ingredients to form the processed cheese. [0003] The use of blended natural cheeses to prepare process cheese often constrains the manufacturing process because natural cheese has a limited shelf life or otherwise requires expensive, refrigerated storage. For instance, once natural cheese is received in a cheese manufacturing plant for blending into a process cheese, it generally must be used within a fixed timeframe or such raw material may be wasted. Such limitations restrict the flexibility of modern cheese manufacturing equipment and facilities. [0004] Attempts have been made to provide a process cheese base with edible powders wherein the resultant cheese base may be used as a substitute for some or all of the natural cheese normally used in the production of process cheese. For instance, U.S. Pat. No. 6,773,740 (which is owned by the same assignee as the present application and which is incorporated by reference) describes a method for preparing a process cheese base for use in preparing process cheese. That method comprised (1) mixing one or more concentrated powders derived from milk with sodium chloride, milk fat, water, and, optionally, an edible acid and a preservative for a period of time sufficient to produce a mixed product, wherein the concentrated powders are present in an amount ranging from about 25 to about 60 percent, wherein the sodium chloride is present in an amount ranging from about 0.5 to about 4.0 percent, wherein the milk fat is present in an amount ranging from about 9 to about 38 percent, wherein the edible acid is present in an amount ranging from 0 to about 2.0 percent, wherein the preservative is present in an amount ranging from 0 to about 0.2 percent, wherein the water is present at a level sufficient to form the cheese product, wherein percentages are based on the total weight of the cheese product, and wherein the milk fat during mixing is at a temperature of about 80 to about 140.degree. F.; and (2) cooling the mixed product for a time and at a temperature which is sufficient to allow the mixed product to form a solid matrix, wherein the solid matrix is the cheese product; wherein the cheese product has the texture and consistency of fresh cheese. [0005] Although this method represents a significant improvement over the prior art, it still has some limitations and disadvantages. Thus, for example, the mixing is carried out at elevated temperatures and formation of the solid matrix requires cooling. For use in process cheese, the solid matrix, which is "hard and difficult to cut," must be ground. Additionally, the solid matrix of U.S. Pat. No. 6,773,740 is not as stable to microbiological growth as is desired. Thus, it must be used immediately or stored under refrigeration conditions. Perhaps more importantly, the equipment used to prepare the solid matrix must be shut down to be cleaned and sanitized on essentially a daily basis. Such daily shutdowns for cleaning and sanitizing increase expenses, promote inefficiencies in the manufacturing process, and constrain the planning and scheduling of process equipment that may be in high demand to produce product. [0006] It would be desirable to provide a process that would avoid or eliminate these shortcomings. The present invention provides such an improved process by producing a friable, non-dusting solid cheese base that is microbiologically stable without refrigeration for extended periods. This cheese base can be used as a substitute for natural cheese in the manufacture of process cheese or other dairy products. The production of the cheese base does not require cooling or additional processing (i.e., grinding) for use in conventional cheese manufacturing equipment. Moreover, an essentially continuous process can be carried for the production of the cheese base and process cheese therefrom. SUMMARY OF THE INVENTION [0007] A cheese base or an intermediate dairy mixture is provided that is suitable for forming a dairy product, such as processed cheese, cream cheese, yogurt and the like, upon subsequent hydration and cooking. The intermediate dairy mixtures have a composition that minimizes agglomeration of protein during the subsequent hydration and formation of the dairy product; therefore, the resultant dairy products have a smooth texture without any visible specks or detectable grittiness. In a preferred embodiment, the dairy mixtures may be used as a partial or complete replacement for natural cheese in the manufacture of processed cheese. In a preferred embodiment, the dairy mixtures are prepared and then used directly in the preparation of process cheese in an essentially continuous process. [0008] The intermediate dairy mixtures also include an amount of water sufficient to render the mixtures non-dusting and friable, which permit ease of handing and elimination of additional grinding steps prior to further processing. As further described below, even though the intermediate dairy mixtures include water, the mixtures are also stable from microbiological growth for greater than 5 days. Such stability permits non-refrigerated storage and extended manufacturing runs with less frequent shutdowns for equipment cleaning and sanitation. [0009] In one form, the intermediate dairy mixture includes a protein powder (preferably milk protein concentrate) having greater than 40 percent protein blended with a dairy powder (preferably whey powder) having greater than about 70 percent lactose, in an amount effective to minimize agglomeration of the protein during subsequent hydration of the mixture. [0010] The protein powder, dairy powder, water, and salt are combined and blended at ambient temperatures (preferably about 60 to about 75.degree. F.) to form the intermediate dairy mixture. Preferably, the ingredients are continuously blended in an extruder, but may also be mixed in a blending tank or other suitable mixer. If desired, the protein powder, the dairy powder, and salt may be first blended together to form a pre-blend to which the water may then be added to form the intermediate dairy mixture upon mixing. The amounts of the various ingredients are adjusted, as described herein, to provide a non-dusting and friable solid that is stable from microbiological growth at room temperature for greater than about 5 days and can be used to prepare a dairy product (e.g., process cheese) having a substantially smooth texture. Since the solid dairy mixture is friable, it can be used directly in a conventional process cheese manufacturing process without further processing steps (i.e., grinding the solid dairy mixture is not necessary). Optionally, an amount of fat, such as a milk fat or vegetable fat, may be added to the intermediate dairy mixture. For instance, between 0 and about 40 percent fat may be added to the intermediate dairy mixture if desired. [0011] The present invention provides a solid dairy mixture comprising: (1) about 5 to about 86 percent of a protein powder having greater than about 40 percent protein; (2) about 5 to about 86 percent of dairy powder having at least about 70 percent lactose; (3) about 5 to about 35 percent water; and (4) about 4 to about 20 percent salt, wherein the ratio of protein powder to dairy powder in the solid dairy mixture is in the range of about 17:1 to about 1:17, wherein the ratio of water to salt in the solid dairy mixture is less than about 6.2, wherein the solid dairy mixture has a water activity less than about 0.87, wherein the solid dairy mixture is non-dusting and friable; wherein the solid dairy mixture is stable from microbiological growth at room temperature for greater than about 5 days, and wherein the solid dairy mixture can be used to prepare a dairy product having a substantially smooth texture. [0012] The present invention also provides a method for preparing a solid dairy mixture, the method comprising: (1) combining about 5 to about 86 percent of a protein powder having greater than about 40 percent protein, about 5 to about 86 percent of whey powder having at least about 70 percent lactose, about 5 to about 35 percent water, and 4 to about 20 percent salt at ambient temperatures to form a mixture; and (2) blending the mixture at ambient temperatures and for a time sufficient to form the solid dairy mixture; wherein the ratio of protein powder to whey powder in the solid dairy mixture is in the range of about 17:1 to about 1:17, wherein the ratio of water to salt in the solid dairy mixture is less than 6.2, wherein the solid dairy mixture has a water activity less than about 0.87, wherein the solid dairy mixture is non-dusting and friable; and wherein the solid dairy mixture can be used to prepare a dairy product having a substantially smooth texture. [0013] This invention also provides a solid dairy mixture prepared by a method comprising: (1) combining about 5 to about 86 percent of a protein powder having greater than about 40 percent protein, about 5 to about 86 percent of dairy powder having at least about 70 percent lactose, about 5 to about 35 percent water, and 4 to about 20 percent salt at ambient temperatures to form a mixture; and (2) blending the mixture at ambient temperatures and for a time sufficient to form the solid dairy mixture; wherein the ratio of protein powder to dairy powder in the solid dairy mixture is in the range of about 17:1 to about 1:17; wherein the ratio of water to salt in the solid dairy mixture is less than 6.2, wherein the solid dairy mixture has a water activity less than about 0.87, wherein the solid dairy mixture is non-dusting and friable; and wherein the solid dairy mixture can be used to prepare a dairy product having a substantially smooth texture. [0014] The non-dusting and friable solid dairy mixtures as described above may also be used to form a process cheese. Accordingly, the invention further provides a method of manufacturing a process cheese by hydrating the non-dusting and friable solid dairy mixture to form a hydrated dairy mixture; treating the hydrated dairy mixture with shear to form a fresh cheese; and blending emulsifiers with the fresh cheese at a time and temperature sufficient to obtain the process cheese. DESCRIPTION OF THE PREFERRED EMBODIMENTS [0015] A intermediate dairy mixture is provided that is suitable as a base ingredient in the manufacture of a variety of dairy products such as process cheese, cream cheese, yogurt, and other dairy-based like products. In a preferred embodiment, the intermediate dairy mixture is a process cheese base, which may be used as a partial or complete replacement for natural cheese in process cheese manufacture. [0016] The intermediate dairy mixtures described herein are non-dusting and friable. Such properties render the mixtures very easy to handle and transport. The friable characteristics also eliminate any additional grinding prior to further use because the dairy mixture is readily crumbled or broken without the use of additional mechanical grinding equipment. For purposes herein, friable means the intermediate dairy mixture is readily crumbled under low shear conditions and thus does not require the use of grinding, pulverizing, or other mechanical high shear equipment to break the intermediate dairy mixture into a crumb-like material for use in conventional process cheese manufacturing processes. Such properties are advantageous because the intermediate dairy mixtures permit flexibility in manufacturing and simplified material handling. [0017] The intermediate dairy mixtures are also stable from microbiological growth for at least about 5 days at ambient temperatures. Thus, extended non-refrigerated storage is possible. Even with increased levels of water, the intermediate dairy mixtures have a composition that limits, and preferably inhibits, the growth of microbes, yeast, and mold for at least about 5 days at ambient temperatures. Such stability effectively eliminates the need for daily equipment cleanings for manufacturing lines using the intermediate dairy mixtures and thus allows for more continuously operation. The intermediate dairy mixtures of the present invention permit less frequent equipment cleanings (e.g., weekly or bi-weekly). [0018] In one form, the intermediate dairy mixture includes a high protein powder, a dairy power, and salt with an amount of water to form a friable, non-dusting mixture. The amount of water and salt in the intermediate dairy mixture are adjusted to achieve a water activity less than or equal to about 0.87, and preferably less than or equal to 0.80. Such water activities provide stability from microbiological growth for at least about 5 days at ambient temperatures. Optionally, the intermediate dairy mixture may also include an amount of fat, such as a milk fat or a vegetable fat. [0019] A wide variety of concentrated powders derived from milk may be employed as the high protein powder. For example, the high protein powder may be a concentrated dairy protein powder, such as non-fat dry milk (NFDM), milk protein powders (i.e., milk protein concentrates, milk protein isolates, casein powder, or caseinate powder), whey protein concentrate, whey protein, or mixtures thereof. Preferably, the high protein powder is a milk protein concentrate (MPC) having at least 40 percent crude protein (and preferably at least about 56 percent crude protein), which renders the intermediate dairy mixture suitable for use as a process cheese base or intermediate base useful in the manufacture of process cheese. Suitable milk protein powders are commercially available with crude protein amounts ranging from about 40 to about 85 percent from New Zealand Milk Products (New Zealand), Murray Goulburn (Australia), and other commercial suppliers. [0020] When using such high protein powders in the manufacture of process cheese, proper hydration of the powders is important to achieve the desired smooth texture in the final product. It has been discovered that the use of a high protein powder or a combination of high protein powders by itself or themselves results in a final product that, upon subsequent hydration, is gritty or includes visible specks. While not wishing to be limited by theory, it is believed that such gritty texture is the result of uneven hydration of the protein powder during the subsequent processing steps. Continue reading about Intermediate dairy mixture and a method of manufacture thereof... 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